Led lens assemblies, led modules and led light fixtures

ABSTRACT

The present invention relates to a LED lens assembly including a lens base, a plurality of lens elements on the lens base, a cable channel on the lens base, a frame at the periphery of the lens base, and clips on the frame. A bottom portion of the frame defines a lip, external to which there is formed a groove for receiving overfill of a sealant. Each of the clips has a trailing portion extending to an edge of the frame. The invention further provides a LED module and a LED light fixture, both incorporating the LED lens assembly. Use of this structure can lead to the following beneficial effects: convenience in mounting; better waterproofing results; and applicability in light used in an obliquely upward orientation, such as flood lights.

TECHNICAL FIELD

The present invention relates to the field of lighting and, moreparticularly, to LED lens assemblies, and LED modules and LED fixturesincorporating the LED lens assemblies.

BACKGROUND

In the current context of concerns about global energy shortage risingonce again, energy conservation and use of new energy have become atheme that the society should pay common attention to. In the field oflighting, the application of LED lighting products is attracting theworld's attention. As new “green” lighting products, LEDs will surely bethe future trend of lighting, and the twenty-first century will be anera of new lighting sources with LEDs as the mainstream.

Most conventional LED lenses commonly available in the market aredesigned to be fixed on a heat dissipation means by means of screws.This design is not convenient for mounting and maintenance. There arealso a small number of LED lenses using clips, examples of which includethose described in Chinese Patent Nos. CN201836825U, CN201836842U andCN103256559A. Each of these lenses is configured to be deployed over acircuit board that is fixed on a heat dissipation means, and essentiallyincludes: a lens base; lens elements arranged on the lens base; channelsfor housing screws and cables; seal ring grooves; and clips that arearranged at a periphery of the lens base and adapted to connect the heatdissipation means.

Conventional LED modules commonly resort to a resilient sealing ring orsealant-filled surface groove for their waterproofness and incorporate athermally conductive bottom plate made of an aluminum alloy material.Such design suffers from insufficient water-proofing andheat-dissipating abilities and inconvenience in mounting andmaintenance.

SUMMARY

It is therefore the object of the present invention to provide LED lensassemblies, and LED modules and LED fixtures incorporating the LED lensassemblies, which overcome the inconvenient mounting, unsatisfactorywaterproofing and inadequate sealing problems arising from the use ofconventional LED lens products.

In pursuit of this object, according to an aspect of the presentinvention:

a LED lens assembly includes a lens base, a plurality of lens elementson the lens base, a cable channel on the lens base, a frame at theperiphery of the lens base, and clips on the frame. A bottom portion ofthe frame defines a lip, next to which a groove for receiving overfillof a sealant is formed. Each of the clips has a trailing portionextending to an edge of the frame.

Additionally, the cable channel may have a height that is greater than 1mm, with 1-2 mm being more preferred.

Further, alternatively, two grooves for receiving overfill of thesealant may be formed on opposing sides of the lip.

Further, the number of the clip may be 3-20.

Further, the lens base may assume a triangular, rectangular, pentagonal,hexagonal, heptagonal, octagonal, round or elliptical shape.

Further, an arrow may be marked on the lens base in order to indicate adirection of the LED lens assembly.

According to another aspect of the invention, a LED module includes theLED lens assembly as defined above.

In addition, the LED module may include, from the bottom upward, aheat-conducting bottom plate, a heat-conducting aluminum base plateattached thereon with a plurality of LEDs, and the LED lens assembly.

The heat-conducting bottom plate has a mounting surface defining a cableoutlet hole, and the heat-conducting aluminum base plate defines anothercable outlet hole. A recess for receiving a resilient sealing ring isprovided between the cable outlet hole in the heat-conducting aluminumbase plate and the cable outlet hole in the heat-conducting bottomplate. A cable extends successively through the cable outlet hole in theheat-conducting bottom plate, the resilient sealing ring and the cableoutlet hole in the heat-conducting aluminum base plate and has a portionreceived in the cable channel of the LED lens assembly and weldedtherein to the heat-conducting aluminum base plate. The resilientsealing ring is fixed within the recess by an adhesive filled thereinsuch that a waterproof seal is formed.

At least one sealing groove is formed in the heat-conducting bottomplate, alongside its periphery. A waterproof seal is formed by filling asealant in the sealing groove and further inserting the lip on thebottom portion of the frame, during which any overfill of the sealant isreceived within the groove external to the lip.

A heat-conducting silicon resin is applied between the heat-conductingaluminum base plate and the heat-conducting bottom plate.

The heat-conducting aluminum base plate is fastened on theheat-conducting bottom plate either by screws or by a piece ofdouble-sided adhesive tape that is thermally conductive.

The LED lens assembly is also fastened on the heat-conducting bottomplate through the clips after the filling of the sealant.

The heat-conducting bottom plate is provided with securing mechanismsdistributed along its periphery or two opposing edges.

The heat-conducting bottom plate defines at least one cable outletgroove.

Further, at least one LED lamp may be further provided on theheat-conducting aluminum base plate.

Further, the heat-conducting bottom plate may have protruding portionsmatching the respective clips.

Further, the heat-conducting bottom plate may be fabricated from amaterial with a thermal conductivity of higher than 90 W/m·K, selectedfrom silicon carbide, copper, aluminum, aluminum alloys, graphite andceramics.

Further, the heat-conducting bottom plate may have a height of 3-30 mm.

According to yet another aspect of the invention, a modular LED lightfixture includes a fixture body, waterproof plugs or sealing rings, anda LED-module cable. The fixture body is provided thereon with a mountingsurface, an electrical component box and cooling fins. One or more LEDmodules as defined above are mounted on the mounting surface.

In addition, in order for waterproof sealing, the LED-module cable mayextend through at least one of the waterproof plugs or sealing rings anda cable inlet bore, into the electrical component box.

Further, the cable inlet bore may be tilted at an angle of 0-180°, morepreferably, 5-175°, with respect to the mounting surface.

The present invention provides the following benefits:

(1) It allows more convenient and reliable mounting.

(2) Improved waterproofness is resulted from the reception of overfillof a liquid silica gel in groove(s) formed next to the sealing groove.

(3) Each of the clips has a strength-improved trailing portion and henceobtains improved ruggedness.

(4) The frame 0.2-5 mm higher than the highest internal portion resultsin improved ruggedness and less deformability of the lens base and makesit possible to block a large amount of rainwater from flowing onto thelens base, which can affect the light distribution or emissionperformance.

(5) LED light fixtures according to the present invention use LEDmodules not equipped with heat dissipation means and rely instead on theheat dissipation means on their fixture bodies for heat dissipation.This leads to the advantages of convenience in mounting and maintenance,high versatility, low replacement cost, and modifiability for use invarious light fixtures with heat dissipation means.

(6) LED light fixtures according to the present invention have goodwaterproof performance ensured by multiple waterproof featuresincluding: one or more waterproof plugs or sealing rings and a cableinlet bore in the fixture body arranged in the path of each cableextending into an electrical component box, an waterproof adhesivefilled in gaps between lenses and between lenses and the heat-conductingbottom plate, of each LED module; and sealant-sealed resilient sealingrings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a clip in a LED lens assemblyconstructed in accordance with Embodiment 1 of the present invention.

FIG. 2 is a schematic, three-dimensional view of the LED lens assemblyconstructed in accordance with Embodiment 1 of the present invention.

FIG. 3 shows a cutaway view taken along line A-A of FIG. 2 and anenlarged view of the portion I, of the LED lens assembly constructed inaccordance with Embodiment 1 of the present invention.

FIG. 4 is a schematic, three-dimensional view of a LED moduleincorporating a LED lens assembly, constructed in accordance withEmbodiment 2 of the present invention.

FIG. 5 is a cutaway view of the LED module incorporating the LED lensassembly constructed in accordance with Embodiment 2 of the presentinvention, taken along line B-B of FIG. 4.

FIG. 6 is another cutaway view of the LED module constructed inaccordance with Embodiment 2 of the present invention, taken along lineB-B of FIG. 4, in which the LED lens assembly is not shown.

FIG. 7 is a schematic showing a structure in accordance with Embodiment3 of the present invention.

FIG. 8 is a schematic showing a structure in accordance with Embodiment4 of the present invention.

FIG. 9 is a schematic showing a structure in accordance with Embodiment5 of the present invention.

FIG. 10 is a schematic showing a structure in accordance with Embodiment6 of the present invention.

FIG. 11 is a schematic showing a structure in accordance with Embodiment7 of the present invention.

DETAILED DESCRIPTION

LED lens assemblies, and LED modules and LED fixtures incorporating theLED lens assemblies according to the present invention are described ingreater detail below with reference to several exemplary embodiments,taken in conjunction with the accompanying drawings. It is to beunderstood that the embodiments set forth below are for the purpose ofillustrating the invention rather than limiting its scope.

Embodiment 1 LED Lens Assembly

As shown in FIGS. 1 to 3, a LED lens assembly according to thisembodiment 1 includes a lens base 1; a plurality of lens elements 2 anda cable channel 3, on lens base 1; a frame 4 at the periphery of lensbase 1; and clips 5 on the frame 4. In a bottom surface of frame 4, agroove 7 for receiving overfill of a sealant is defined external to (onthe right as shown in the figures in connection with the description ofthis embodiment) a lip 6 projecting from the bottom surface. Lip 6 canprevent an insufficient sealing effect caused by overfill of thesealant. Frame 4 is 0.2-5 mm higher than the highest internal portion,thus resulting in improved ruggedness and less deformability of lensbase 1 and making it possible to block a large amount of rainwater fromflowing onto lens base 1 to affect the light distribution or emission.In this embodiment, lens base 1 is a square, and the cable channel isdesigned to have a height of 1-2 cm. This can result in improvedruggedness and less deformability of lens base 1, thereby preventingchanges in light distribution curves and failure of waterproofness thatmay be caused by deformation of lens base 1. The number of clips 5arranged at the periphery of lens base 1 is 3-30, and each of clips 5has a trailing portion extending to an edge of frame 4 and thus hasimproved ruggedness. Further, the lens base is provided an arrow 8marked thereon for indicating a direction of the LED lens assembly.

Embodiment 2 LED Module Incorporating LED Lens Assembly

FIGS. 4 to 6 show a LED module incorporating a LED lens assemblyconstructed in accordance with Embodiment 1. The LED module includes,from the bottom upward, a heat-conducting bottom plate 10, aheat-conducting aluminum base plate 11 attached with a plurality ofLEDs, and the LED lens assembly indicated at 12. Cable outlet holes 13and 14 are formed respectively in a mounting surface of heat-conductingbottom plate 10 and in heat-conducting aluminum base plate 11. A recess16 for receiving a resilient sealing ring 15 is provided between cableoutlet hole 14 in heat-conducting aluminum base plate 11 and cableoutlet hole 13 in heat-conducting bottom plate 10. A cable 17 extendssuccessively through cable outlet hole 13, resilient sealing ring 15 andcable outlet hole 14, and has a portion received in cable channel 3 ofLED lens assembly 12 and welded therein to heat-conducting aluminum baseplate 11. Resilient sealing ring 15 is fixed within recess 16 after anadhesive is filled therein, thus forming a waterproof seal. A sealinggroove 19 is defined in the heat-conducting bottom plate 10 alongsideits periphery. With a sealant filled in sealing groove 19, a waterproofseal is formed by inserting lip 6 projecting from the bottom surface offrame 4 of LED lens assembly 12 in sealing groove 19. During thisprocess, any overfill of the sealant will be received within groove 7that is external to lip 6. A heat-conducting silicon resin is appliedbetween heat-conducting aluminum base plate 11 and heat-conductingbottom plate 10. Heat-conducting aluminum base plate 11 is fastened onheat-conducting bottom plate 10 either by screws 20 or by a piece ofdouble-sided adhesive tape that is thermally conductive. LED lensassembly 12 is further fastened on heat-conducting bottom plate 10 bymeans of clips 5 after the filling of the sealant, in such a mannerthat, after the fastening, the clips reach a level not higher than themounting surface of heat-conducting bottom plate 10. Heat-conductingbottom plate 10 is provided with mounting holes 21 distributed along itsperiphery or two opposing edges, and has protruding portions 22 matchingthe respective clips. 10-50 LED lamps 23 are disposed on heat-conductingaluminum base plate 11. In addition, in a backside of heat-conductingbottom plate 10, there is formed a cable outlet groove 24 leading fromcable outlet hole 13. Heat-conducting bottom plate 10 is fabricated froma material with a thermal conductivity higher than 90 W/m·K, selectedfrom silicon carbide, copper, aluminum, aluminum alloys, graphite andceramics.

Embodiment 3 Modular LED Light Fixture

FIG. 7 shows a LED light fixture using LED modules constructed inaccordance with Embodiment 2. The fixture includes a fixture body 101,on which there are arranged 4 mounting surfaces 102, an electricalcomponent box 104, a band clamp 105 for securing a mounting bracket andcooling fins 106. Electrical component box 104 is disposed betweenadjacent ones of mounting surfaces 102. Band clamp 105 and cooling fins106 are arranged on the periphery of fixture body 101. Each of mountingsurfaces 102 is provided with a LED module 103, a waterproof plug 107and a cable inlet bore 108 tilted at an angle of 5-175° (−5-175°).Cables for LED module 103 are coupled to a power supply and extend intoelectrical component box 104 via respective waterproof plugs 107 andcable inlet bores 108. Preferably, each of LED modules 103 is fastenedto one of mounting surfaces 102 by means of 8 screws. In thisembodiment, LED modules 103 are not provided with any heat dissipationmeans and heat generated by them after they are mounted on the lightfixture is dissipated via the cooling means on fixture body 101.

Embodiment 4 Modular LED Light Fixture

FIG. 8 shows a modular LED light fixture in another form, including afixture body 201 and a cover 208. On fixture body 201, there areprovided a mounting surface 202, an electrical component box (notshown), cooling fins 206 and a mounting bracket 207. Mounting surface202 and the electrical component box are disposed in a lower portion offixture body 201. Cooling fins 206 are arranged on a surface of fixturebody 201. Mounting bracket 207 is attached to a side face of fixturebody 201. Mounting surface 202 defines a cable inlet bore 205 and bearsa LED module 203. A cable 204 for LED modules 203 is connected to apower supply and extends into the electrical component box via cableinlet bore 205. Preferably, LED module 203 is fastened to mountingsurface 202 by means of 8 screws. Cover 208 is mounted on fixture body201 by 4 screws, and a sealing ring 209 is disposed between cover 208and fixture body 201 for imparting waterproofness to the light fixture.In this embodiment, LED module 203 is not provided with any heatdissipation means and heat generated from it after it is mounted on thelight fixture is dissipated via the cooling means on fixture body 201.

Embodiment 5 Modular LED Light Fixture

FIG. 9 shows a modular LED light fixture in yet another form, includinga fixture body 301. On fixture body 301, there are provided a mountingsurface 302, an electrical component box (not shown) and cooling fins307. Cooling fins 307 are arranged on a bottom side of fixture body 301.Mounting surface 302 bears two LED modules 303 mounted thereon anddefines waterproof plugs 305 and cable inlet bores 306 each tilted at anangle of 5-175° (−5-175°). Cables 304 for LED modules 303 are coupled toa power supply and extend into the electrical component box viarespective waterproof plugs 305 and cable inlet bores 306. Preferably,each of LED modules 303 is fastened to mounting surface 302 by means of8 screws. In this embodiment, LED modules 303 are not provided with anyheat dissipation means and heat generated by them after they are mountedon the light fixture is dissipated via the cooling means on the fixturebody 301.

Embodiment 6 Modular LED Light Fixture

FIG. 10 shows a modular LED light fixture in still another form,including a fixture body 401 and a cover 408. On fixture body 401, thereare provided a mounting surface 402, an electrical component box (notshown), a mounting bracket 407 and cooling fins 406. Cooling fins 406and mounting bracket 407 are arranged on the periphery of fixture body401. Mounting surface 402 and the electrical component box are disposedin a lower portion of fixture body 401. A LED module 403 is mounted onmounting surface 202 that defines a cable inlet bore 405. A cable 404for the LED modules 403 is coupled to a power supply and extends intothe electrical component box via cable inlet bore 405. Preferably, LEDmodule 403 is fastened to mounting surface 402 by means of 8 screws.Cover 408 is mounted on fixture body 401 by 6 screws, and a sealing ring409 is disposed between cover 408 and fixture body 401 for impartingwaterproofness to the light fixture. In this embodiment, LED module 403is not provided with any heat dissipation means and heat generated fromit after it is mounted on the light fixture is dissipated via thecooling means on fixture body 401.

Embodiment 7 Modular LED Light Fixture

FIG. 11 shows a modular LED light fixture in yet still another form,including a fixture body 501. On fixture body 501, there are provided 4mounting surfaces 502, an electrical component box (not shown), a bandclamp 507 for securing a mounting bracket and cooling fins 506. Mountingsurfaces 102 individually bear 4 LED modules 503 mounted thereon andindividually define 4 cable inlet bores 505. Cables 504 for LED modules503 are coupled to a power supply and extend into the electricalcomponent box via respective cable inlet bores 505. Preferably, LEDmodules 503 are fastened to respective mounting surfaces 502 by screws.In this embodiment, LED modules 503 are not provided with any heatdissipation means and heat generated by them after they are mounted onthe light fixture is dissipated via the cooling means on fixture body501.

1. A LED lens assembly, comprising a lens base, a plurality of lenselements on the lens base, a cable channel on the lens base, a frame atthe periphery of the lens base, and clips on the frame, wherein a bottomportion of the frame defines a lip, next to which a groove for receivingoverfill of a sealant is formed, and wherein each of the clips has atrailing portion extending to an edge of the frame.
 2. The LED lensassembly of claim 1, wherein the cable channel has a height that isgreater than 1 mm.
 3. The LED lens assembly of claim 1, wherein thenumber of the clip is 3-20.
 4. The LED lens assembly of claim 1, whereinthe lens base assumes a triangular, rectangular, pentagonal, hexagonal,heptagonal, octagonal, round or elliptical shape.
 5. The LED lensassembly of claim 1, wherein an arrow is marked on the lens base inorder to indicate a direction of the LED lens assembly.
 6. A LED modulecomprising the LED lens assembly as defined in claim
 1. 7. The LEDmodule of claim 6, comprising, from the bottom upward, a heat-conductingbottom plate, a heat-conducting aluminum base plate bearing a pluralityof LEDs attached thereon, and the LED lens assembly, wherein theheat-conducting bottom plate has a mounting surface defining a cableoutlet hole and the heat-conducting aluminum base plate defines anothercable outlet hole; a recess for receiving a resilient sealing ring isprovided between the cable outlet hole in the heat-conducting aluminumbase plate and the cable outlet hole in the heat-conducting bottomplate; a cable extends successively through the cable outlet hole in theheat-conducting bottom plate, the resilient sealing ring and the cableoutlet hole in the heat-conducting aluminum base plate and has a portionreceived in the cable channel of the LED lens assembly and weldedtherein to the heat-conducting aluminum base plate; and the resilientsealing ring is fixed within the recess by an adhesive filled thereinsuch that a waterproof seal is formed, wherein at least one sealinggroove is formed in the heat-conducting bottom plate, alongside itsperiphery; and a waterproof seal is formed by filling a sealant in thesealing groove and further inserting the lip on the bottom portion ofthe frame, during which any overfill of the sealant is received withinthe groove external to the lip, wherein a heat-conducting silicon resinis applied between the heat-conducting aluminum base plate and theheat-conducting bottom plate, wherein the heat-conducting aluminum baseplate is fastened on the heat-conducting bottom plate either by screwsor by a piece of double-sided adhesive tape that is thermallyconductive, wherein the LED lens assembly is also fastened on theheat-conducting bottom plate through the clips after the filling of thesealant, wherein the heat-conducting bottom plate is provided withsecuring mechanisms distributed along its periphery or two opposingedges, and wherein the heat-conducting bottom plate defines at least onecable outlet groove.
 8. The LED module of claim 7, wherein at least oneLED lamp is further provided on the heat-conducting aluminum base plate.9. The LED module of claim 7, wherein the heat-conducting bottom platehas protruding portions matching the respective clips.
 10. The LEDmodule of claim 7, wherein the heat-conducting bottom plate isfabricated from a material with a thermal conductivity of higher than 90W/m·K, selected from silicon carbide, copper, aluminum, aluminum alloys,graphite and ceramics.
 11. The LED module of claim 7, wherein theheat-conducting bottom plate has a height of 3-30 mm.
 12. A modular LEDlight fixture, comprising a fixture body, waterproof plugs or sealingrings, and a LED-module cable, wherein the fixture body is providedthereon with a mounting surface, an electrical component box and coolingfins, and wherein one or more LED modules as defined in claim 6 and acable inlet hole are mounted on the mounting surface.
 13. The modularLED light fixture of claim 12, wherein in order for waterproof sealing,the LED-module cable extends through at least one of the waterproofplugs or sealing rings and the cable inlet hole, into the electricalcomponent box.
 14. The modular LED light fixture of claim 12, whereinthe cable inlet bore is tilted at an angle of 0-180° with respect to themounting surface.